Stator assembly with cascaded winding and method of making same

ABSTRACT

A stator assembly for a dynamoelectric machine featuring a cascaded construction includes several conductors, each having a plurality of slot segments interconnected by plurality of end loop segments. The consecutive slot segments of a first conductor forms nearly all of a radially-outermost first layer of the stator winding, with the remaining portion of the radially-outermost winding layer being defined by a slot segment of a second conductor that is then inserted into the core to form nearly all of a second layer of the stator winding radially-inwardly of the first winding layer. The second winding layer is completed with an additional single slot segment of the first conductor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No. 10/443,441 filed May 22, 2003 which, in turn, claims benefit of U.S. provisional application No. 60/454,996 filed Mar. 14, 2003, the respective disclosures of each of which are hereby incorporated by reference.

FIELD OF THE INVENTION

The invention relates to cascaded stator winding configurations for dynamoelectric machines, such as an automotive electrical alternator, and methods for making such stator winding configurations using a plurality of conductors.

BACKGROUND OF THE INVENTION

Electrical alternators adapted for use in motor vehicle applications typically include a rotor assembly rotatable within an annular stator. Rotor pole pieces, which may preferably be of an interleaved “claw pole” design, rotate with the rotor shaft, while the stator itself includes a stator core defining radially-extending slots in which a plurality of stator windings are disposed. An excitation winding is carried within the cavity formed between pole pieces of the rotor, and a DC signal is applied to the excitation winding through a pair of slip rings and associated brushes. The magnetic field produced by the winding interacts with the pole pieces to create an alternating polarity magnetic field which, upon rotation of the rotor assembly as driven by the vehicle's engine, induces current flow in the stator windings in a known manner.

Because the resistance of the conductors of the stator windings is inversely proportional to alternator output and efficiency, the resistance and therefore the cross sectional area of the stator winding is an important factor for improving alternator output and efficiency. To achieve higher electrical outputs while reducing the overall size of the stator, the prior art has, therefore, sought to employ stator conductors of square or rectangular cross-section to increase conductor cross sectional area and, hence, improve the performance and efficiency of the dynamoelectric machine. Such wire can be laced into the stator core winding slots in a very densely packed configuration, thereby improving “slot space utilization.” However, square- or rectangular-cross-section wire is more difficult to form and wind into the stator winding slots, since it is necessary to align the conductor cross-section with the slot.

Designers of stator assemblies further attempt to reduce or eliminate the need for providing electrical conductor terminations and connections in the stator assembly. The necessity to physically connect conductors in the stator core assembly adversely impacts cost and complexity of the manufacturing process. A particular technique for winding continuous conductors onto a stator core is disclosed in U.S. Patent Application Publications No. 2003/0137205A1 and No. 2003/0137204A1, each assigned to the assignee of the present invention, which disclosures are hereby incorporated by reference. In these published patent applications, a high-slot-fill, multi-phase stator winding in which each phase is defined by a pair of interleaved conductors that alternate radial positions in each of an adjacent pair of winding layers as the conductors together traverse the core's circumference, except in the “radial shift” areas in which each conductor transitions radially inwardly to together form the next winding layer. The radially-inward winding layer pairs are then inserted atop the first winding layer pair to advantageously provide a stator winding featuring radial-aligned and, therefore, sequentially-inserted winding layers (each of which is defined by pairs of interleaved conductors).

While the above technique thus advantageously provides a radially-aligned layered stator winding, it will be appreciated that the interleaved conductors forming each winding layer pair continues to present manufacturing challenges. Accordingly, there exists a need for a method of forming a multilayered, cascaded stator winding that does not require interleaved conductors.

BRIEF SUMMARY OF THE INVENTION

A stator for a dynamoelectric machine includes a core having a generally cylindrical shape and a plurality of circumferentially-spaced core slots for receiving a cascaded winding. The term cascaded winding, utilized herein, refers to a winding having radial aligned layers as well as radial aligned conductors in each layer which allows the conductors to be sequentially inserted into the core for each layer and for each layer to be sequentially inserted into the core. The stator winding includes a plurality of electrical conductors of square- or rectangular-cross-section. Each conductor includes a pair of leads and a series of slot segments that are interconnected by end loop segments. The conductors may be formed from a continuous wire or for ease of manufacturability, may have connections between individual wires. A connection will usually appear in an end loop segment and, thus, an end loop segment can be formed from a continuous wire or be formed from two wires with a connection between the wires. Preferably, the conductors are structured in phases, as defined by a circumferential pitch.

According to an aspect of the invention, each conductor of a first set of conductors has a first plurality of consecutive slot segments, for example, adjacent to one lead, disposed in a radially-outermost first winding layer of the stator winding, for nearly one complete revolution around the stator core. Each conductor of the first set of conductors also includes an additional, first single slot segment, immediately adjacent to the first plurality of consecutive slot segments, disposed in a second, radially-inward winding layer of the stator winding. Each conductor of a second set of conductors has a first single slot segment, adjacent to one lead, disposed in the winding's first winding layer, and first plurality of consecutive slot segments, immediately adjacent to the first single slot segment, disposed in the second winding layer of the stator winding, for nearly one complete rotation around the stator core.

In accordance with another aspect of the invention, if the stator winding includes a third, cascaded winding layer defined by the slot segments of the first and second sets of conductors, the third winding layer includes a second plurality of consecutive slot segments of each of the first set's conductors that immediately follow its first single slot segment, and a second, additional single slot segment of each of the second set's conductors that immediately follow its first plurality of consecutive slot segments. Similarly, if the stator winding includes a fourth winding layer to be defined by the slot segments of the first and second sets of conductors, the fourth winding layer includes a second, additional single slot segment of each of the first set's conductors that immediately follows its second plurality of slot segments, and a second plurality of consecutive slot segments of each of the second set's conductors that immediately follow its second single slot segment (for example, adjacent to its other lead). Additional winding layers may also be provided using the first and second conductors, in a similar manner.

Thus, it will be seen that, under the invention, the first, radially-outermost winding layer is defined by the first set of conductors (forming nearly all of the first winding layer) and a single slot segment of each of the second set's conductors, adjacent its one lead; and the second winding layer, radially inward and adjacent to the first winding layer, is defined by a single slot segment of each of the first set's conductors, along with a plurality of consecutive slot segments of the second set's conductors.

According to another aspect of the invention, to ease manufacturability of cascaded stator winding, a method includes inserting the slot segments adjacent the leads of a second set of conductors into the “second set lead” slots and inserting nearly all of the slot segments of the second winding layer into the slots of the stator core prior to inserting the first set of conductors into the “second set lead” slots. Thus, the “shifted” slot segments adjacent the leads of the second winding layer will be in the radial position of the slots that define the first winding layer, while a single slot segment of each of the first set's conductors will be in the radial position of the slots that define the second winding layer.

In the event that one or more additional winding layers are desired, the method further includes inserting additional slot segments of the first set's conductors on top of the inserted slot segments of the second set's conductors. The innermost layer, which is defined by a plurality of consecutive slot segments of one set's conductors, is completed by a single slot segment of the other set's conductors.

Additional features, benefits, and advantages of the invention will become apparent to those skilled in the art to which the invention relates from the subsequent description of several exemplary embodiments and the appended claims, taken in conjunction with the accompanying Drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the Drawings, wherein like reference numerals are used to designate like components in each of the several views, and wherein the relative thickness of certain components has been increased for clarity of illustration:

FIG. 1 is a perspective view of an exemplary stator constructed in accordance with the invention;

FIG. 2 is a longitudinal section, partially broken away, of the stator core of FIG. 1;

FIG. 3 is another sectional view of the stator core, taken along line 3-3 of FIG. 2, but showing only four single-conductor layers, without insulation, for clarity of illustration;

FIG. 4 is a partial view in perspective, partially broken away, of a flattened six-conductor, three-phase, four-layer stator winding in accordance with the invention;

FIG. 5 is a perspective view of a complete stator winding, similar to that of FIG. 4, that has been cut at one point on the winding's circumference and flattened to better illustrate the winding's several winding layers;

FIG. 6 is an enlarged partial view of the first two radially-outermost winding layers of the stator winding of FIG. 4, illustrating the two types of end loop segments employed in the winding between cascaded slot segments of a given conductor; and

FIG. 7 is a schematic view illustrating two conductors defining one phase of the stator winding of FIG. 4, prior to insertion into the core.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1-3, an exemplary twelve-conductor, six-phase, eight-layer stator 10 for a dynamoelectric machine, such as an alternator for a motor vehicle (not shown), includes a generally cylindrical stator core 12 and a stator winding 14 disposed in stator slots 16 defined about the inner periphery 18 of the stator core 12. The slots 16 are equidistantly and circumferentially spaced around the core's inner periphery 18, and extend axially through the stator core 12 from one axial end 20 of the core 12 to the other axial end 22 of the core 12.

The stator winding 14 is generally comprised of a plurality of conductors 24 wound around the stator core 12 within the stator slots 16 to thereby define concentric conductor winding layers L. As seen in FIG. 3 (in which only four separate single-conductor winding layers L are illustrated for clarity), in order to achieve a high slot fill, the conductor 24 may be of square or rectangular shape when viewed in cross-section, with the width of the conductor including any insulation being closely matched to the width of the core slots 16, including any insulation (again, not shown in FIG. 3 for clarity of illustration). For those skilled in the art, it is known that typical rectangular or square shaped conductors may include radii on the corners intermediate two adjacent edges. It is further noted that the conductor's square or rectangular cross-sectional shape advantageously increases the surface area of the conductors and, therefore, also increases the convective cooling as air passes through the stator core 12 during operation.

As seen in the partial perspective view of a “cut” and “flattened” stator winding 14 shown in FIG. 4, and in the complete “cut” and “flattened” view of FIG. 5, both of which show a six-conductor, three-phase winding 14 for improved clarity of illustration, the stator winding 14 includes six continuous conductors 24 which are divided into a first set 26 a of three conductors 24 a,24 b,24 c and a second set 26 b of three conductors 24 d,24 e,24 f. Although sets of three conductors are shown, it is obvious to those skilled in the art that sets with any number of conductors could be utilized, such as six which is commonly used in electrical machines. Each conductor 24 includes a pair of leads 28,30 (as best seen in FIG. 5) with which the conductors 24 are electrically interconnected to thereby define a desired number of phases in a desired ring or star configuration. Furthermore, the conductors 24 can be electrically interconnected to thereby define a desired number of phases in a plurality of ring or star configurations, such as a dual wye configuration. Each conductor 24 includes a series of slot segments 32 that are disposed within the slots 16 of the stator core 12 (for reference, the first n slots 16 into which the slot segments 32 of the first conductor 24 a are inserted are designated in FIG. 4 as S₁ through S_(n)).

The slot segments 32 of each conductor 24 are themselves interconnected with end loop segments 34 that extend axially outwardly from the stator core 12 proximate to each stator core face 20,22, as seen in FIG. 1. Returning to FIG. 4, each end loop segment 34 includes a first leg 36 and a second leg 38 which together define an apex 40 of the end loop segment 34.

As best seen in FIG. 6, the winding 14 includes two types of end loop segments 34 a,34 b. In the first type of end loop segment 34 a, the first leg 36 a of one end loop segment 34 interconnecting a pair of consecutive slot segments 32 remains substantially co-radial with a first of the pair of slot segments 32, i.e., remains substantially within the same layer L as the first slot segment 32, until the end loop's apex 40, whereupon a first radial extension 41 a ₁ shifts the conductor 24 radially outwardly (in the direction of Arrow A in FIG. 4) roughly the radial dimension of the conductor 24. The second leg 38 a of the first type of end loop segment 34 a remains substantially radially-outwardly shifted as it approaches the second of the pair of consecutive slot segments 32, whereupon a second radial extension 41 a ₂ shifts the conductor 24 radially inwardly (in the direction of Arrow B in FIG. 4), such that the second slot segment 32 is co-radial with the first.

Referring again to FIG. 6, in the second type of end loop segment 34 b, the first leg 36 b of one end loop segment 34 interconnecting a pair of consecutive slot segments 32 includes a first radial extension 41 b ₁ proximate to the first slot segment 32 that shifts the conductor 24 radially outwardly (in the direction of Arrow A in FIG. 4) roughly the radial dimension of the conductor 24. The first leg 36 b remains radially outwardly of the first slot segment's layer L until the end loop segment's apex 40, whereupon a second radial extension 41 b ₂ shifts the conductor 24 radially inwardly (in the direction of Arrow B in FIG. 4) to a point co-radial with the first slot segment 32. The second leg 38 b of the second type of end loop segment 34 b remains substantially co-radial with the first slot segment 32 until it reaches the second slot segment 32 (which is also co-radial with the first slot segment 32).

In this manner, several consecutive slot segments 32 of a given conductor 24 reside in the same winding layer L of the stator winding 14 for nearly a complete revolution around the stator core 12, thereby providing the resulting winding with a substantially cascaded winding pattern, while further advantageously ensuring that the cascaded layers do not extend radially inwardly beyond the innermost layer L of the winding 14. Together, the conductors 24 define a first, radially-outermost winding layer L₁, and three successively adjacent, cascaded radially-inward winding layers L₂,L₃,L₄ (best seen in FIG. 3).

FIG. 7 is a schematic diagram illustrating the transition of the conductors 24 from one layer to the next layer of the three-phase, four-layer winding pattern of FIGS. 4 and 5, as viewed from what will become the first axial end 20 of the inserted winding 14. For clarity, only the two conductors 24 forming one phase of the three-phase stator winding 14 is illustrated prior to insertion into the stator core 12, with the core slot position in which the respective slot segments 32 are disposed after insertion of the winding 14 into selected ones of the thirty-six slots 16 defined in the stator core 12.

As seen in FIG. 7, in which the end loop segments 34 defining the first stator assembly's first axial end 20 are shown in solid lines, and the end loop segments 34 on the assembly's second axial end 22 are shown in broken lines, the respective first leads 28 of the first and fourth conductors 24 a,24 d, as identified in the preceding Figures, are received in the first slot S₁ and the thirty-fourth slot S₃₄. From the first slot S₁ through the thirty-first slot S₃₁, a respective first plurality of consecutive slot segments 32 of the first and fourth conductors 24 a,24 d define the radially-outermost first layer L₁ and radially-inwardly-adjacent second layer L₂, wherein each end loop segment 34 a,34 b includes an equal number of radially-outward and radially-inward extensions to thereby maintain each of the consecutive slot segments 32 within the conductor's respective winding layer L.

Between the thirty-first slot S₃₁ and the first slot S₁, the two conductors 24 a,24 d, two types of transition area end loop segments 34 c,34 d interconnect slot segments 32 that are disposed in different layers L of the winding 14 and, hence, are characterized by an unequal number of radially-outward and radially-inward extensions. By way of example, the fourth conductor 24 is disposed in the first layer L₁ at the thirty-fourth slot S₃₄, whereupon the adjacent transition area end loop segment 34 c (when moving left to right in FIG. 7) will be seen to include only a single radially-inward extension to thereby locate the immediately-following slot segment 32 in the second layer L₂ at the first slot S₁. By way of further example, after the first conductor 24 a has traversed the stator core 12 in the first layer L₁ to reach the thirty-first slot S₃₁, the immediately adjacent transition area end loop segment 34 c includes only a single radially-inward extension to thereby locate the immediately-following slot segment 32 in the second layer L₂ at the thirty-fourth slot S₃₄. The first conductor's immediately subsequent transition area end loop 34 d includes three radial extensions, specifically, two radially-inward extensions and one radially-outward extension, whereby the immediately following slot segment 32 of the first conductor 24 a is disposed in the third layer L₃ at the first slot S₁.

Referring again to FIG. 4, and describing the winding the first and fourth conductors 24 a,24 d of a particular phase for clarity of illustration, a first plurality of consecutive slot segments 32 a ₁ of the first conductor 24 a are disposed in the slots 16 of the stator core 12 to define nearly a complete revolution of the first winding layer L₁, beginning at core slot S₁. Before the first conductor 24 a can be inserted into the last core slot S_(n) of the first winding layer L₁, the fourth conductor 24 d is disposed in the last core slot S_(n) to thereby define a portion of the first winding layer L₁ with a single slot segment 32 d ₁ immediately adjacent to its starting lead 28 d.

With the single slot segment 32 d ₁ occupying the last core slot S_(n) to thereby define a portion of the first winding layer L₁, the first conductor 24 a is disposed in core slot S_(n) to thereby define the first slot segment 32 a ₂ of the second winding layer L₂. A first plurality of consecutive slot segments 32 d ₂ of the fourth conductor 24 d are disposed in core slots S₁ through S_(n-1) to thereby define nearly a complete revolution of the second winding layer L₂, while a second plurality of consecutive slot segments 32 a ₃ of the first conductor 24 a are disposed radially inward of these fourth conductor slot segments 32 d ₂ into core slots S₁ through S_(n-1) to thereby define nearly a complete revolution of the third winding layer L₃.

The fourth conductor 24 d is disposed in core slot S_(n-1) to thereby complete the second winding layer L₂, a second single slot segment 32 d ₃ of the fourth conductor 24 d is disposed in core slot S_(n) to define a portion of the third winding layer L₃ in that slot S_(n), whereupon the fourth conductor 24 d is further disposed in the stator core 12 to thereby define nearly all of a fourth winding layer L₄ at core slots S₁ through S_(n-1) (best seen in FIG. 5). A second single slot segment 32 a ₄ (seen in FIG. 5) of the first conductor 24 a, is disposed in core slot S_(n) radially inward of the second single slot segment 32 d ₃ of the fourth conductor 24 d, completes the fourth winding layer L₄.

The other conductors 24 b,24 c of the first conductor set 26 a are disposed in the core slots 16 in a like manner as the first conductor 24 a, but for their relative circumferential positions about the stator core 12. Similarly, the other conductors 24 e,24 f of the second conductor set 26 b are disposed in the core slots 16 in a like manner as the fourth conductor 24 d, but for their relative circumferential positions about the stator core 12. In this manner, the slot segments 32 of the conductors 24 of all of the phases in the radially-outermost slot position define the first winding layer L₁, whereupon the slot segments 32 of the conductors 24 fill increasingly-radially-inward positions within the stator core's slots 16.

Also as best seen in FIG. 4, the end loop segments 34 a,34 b of the several conductors 24 overlap to thereby permit consecutive slot segments 32 of each conductor 24 to traverse the stator core 12 within a given winding layer L. Specifically, the legs 36,38 of the conductor's end loop segments 34 permit several conductors 24 to be positioned in a cascaded structure having a suitable number of phases. By way of example only, the exemplary stator 10 has three phases, respectively defined by the first and fourth conductors 24 a,24 d, the second and fifth conductors 24 b,24 e, and the third and sixth conductors 24 c,24 f. Although only three phases have been shown, those skilled in the art will realize any number of phases could be utilized, such as six.

Thus, when the first set 26 a of conductors 24 a,24 b,24 c have made nearly one complete revolution around the stator core 12, the respective transition area end loop segments 34 c on the axial end 22 connecting each conductor's next-to-last slot segment 32 (such as the slot segment 32 a, disposed in slot S_(n-1)) from the last slot segment 32 (such as the slot segment 32 a ₂ disposed in slot S_(n)) defines a radial extension that shifts the respective conductor 24 a,24 b,24 c radially inwardly, such that the conductor's last slot segment 32 is positioned in the next, immediately-radially-inward winding layer L₂. Similarly, the transition area end loop segments 34 d on the axial end 20 connecting each conductor's last slot segment 32 in a given layer L (such as 32 a ₂ disposed in slot S_(n)) from the following slot segment 32 in a different layer L (such as 32 a ₃ disposed in slot S₁) each define a radial extension that shifts the respective conductor 24 a,24 b,24 c radially inwardly, such that the following slot segment (32 a ₃) is positioned in the next, immediately-radially-inward winding layer (in this case, the third layer L₃).

And, when the first set 26 a of conductors 24 a,24 b,24 c completes the remainder of the winding layer L₃, the transition area end loop segment 34 c located on the axial end 22 separating the next-to-last slot segment 32 from the last slot segment 32 of the conductors 24 a,24 b,24 c (adjacent to the ending leads 30) defines a radial extension that shifts the respective conductors 24 a,24 b,24 c radially inward, such that the conductors last slot segment adjacent the ending leads 30 is positioned in the radially-innermost fourth layer L₄.

With respect to the second set 26 b of conductors, the first slot segments 32 adjacent the leads 28, such as slot segment 32 d ₁ disposed in slot S_(n), is located in layer L₁. The transition area end loop segments 34 c located on the second axial end 22 of the core, which connect the first slot segments 32 (disposed in slot S_(n)) with the second slot segments 32 (disposed in slot S₁) defines a radial extension that shifts the respective conductors 24 d,24 e,24 f radially inward, such that the second slot segments are disposed in the next, immediately-radially-inward layer L₂. When the second set 26 a of conductors 24 d,24 e,24 f have made nearly one complete revolution around the stator core 12 disposed in layer L₂, the respective transition area end loop segment 34 d on the axial end 20 connecting the last slot segment 32, (such as slot segment 32 d ₂ disposed in slot S_(n-1)) from the immediately-following slot segment 32 (such as slot segment 32 d ₃ disposed in slot S_(n)) of the conductors 24 d,24 e,24 f defines a radial extension that shifts the respective conductor 24 d,24 e,24 f radially inwardly, such that the conductor's next slot segment 32 is positioned in the next, immediately-radially-inward winding layer L₃.

Furthermore, the transition area end loop segment 34 c on the second axial end 22 connecting, for example, the fourth conductor's next slot segment 32 d ₃ (disposed in slot S_(n)) from the following slot segment 32 d ₄ (disposed in slot S₁) defines a radial extension that shifts the conductor 24 d radially inwardly, such that slot segment 32 d ₄ is positioned in the next, immediately-radially-inward winding layer L₄. In this manner, transition area end loop segments 34 c,34 d that shift a conductor radially inward to thereby interconnect slot segments 32 disposed in different layers include a radial extension in the inward direction by having at least one more inward radial extension or adjustment than the number of outward radial extensions or adjustments.

As seen in FIG. 4, certain transition area end loop segments certain special end loop segments 34 c are characterized by one inward radial adjustment and zero outward radial adjustments, while other transition area end loop segments 34 d are characterized by two inward radial adjustments and one outward radial adjustment. For a stator having L number of layers, the number of transition area end loop segments 34 c,34 d which interconnect two slot segments 32 disposed in different layers is equal to 2L−2 per phase. For a stator having P number of electrical poles, the number of total end loop segments 34 per phase is equal to (P−1)*L. Therefore, a stator having eight Poles and eight layers has fifty-six total number of end loop segments 34 per phase, of which fourteen end loop segments are transition area end loop segments 34 c,34 d interconnecting slot segments 32 disposed in different layers L. This results in a winding 14 in which 25% of the end loop segments 34 are transition area end loop segments 34 c,34 d.

Furthermore, a stator having ten Poles and four layers has thirty-six total number of end loop segments 34 per phase, of which six end loop segments 34 are transition area end loop segments 34 c,34 d connecting slot segments 32 in different layer. This results in a winding 14 in which 16.7% of the end loop segments 34 are transition area end loop segments 34 c,34 d. Conversely, for the two mentioned cases, the winding 14 respectively includes 75% and 83.3% of all end loop segments 34 connect two slot segments 32 disposed in the same layer. Consequently, the winding 14 for the two respective cases respectively includes 25% and 16.7% of the end loop segments 34 are transition area end loop segments 34 c,34 d, characterized by having one more radial inward adjustment than outward adjustments.

FIG. 5 shows a complete stator winding 14, cut at one point and “flattened” for ease of illustration. Following each conductor 24 from one starting lead 28 towards the first cut end 42 and then again from the second cut end 44 back towards the ending leads 30, the stator winding 24 has a cascaded construction as discussed above, with the first set 26 a of conductors 24 a,24 b,24 c defining nearly all of the radially-outermost first winding layer L₁, an initial portion of the intermediate second winding layer L₂, nearly all of the third winding layer L₃ and an initial portion of the radially-innermost fourth winding layer L₄.

The second set 26 b of conductors 24 d,24 e,24 f define the remaining portion of the radially-outermost first winding layer L₁, nearly all of the second winding layer L₂, an initial portion of the third winding layer L₃, and nearly all of the radially-innermost fourth winding layer L₄. The two conductors, such as 24 a and 24 d, could be formed of one continuous wire. This can be achieved by an incorporating an auxiliary continuous end loop (not shown) between the two leads 30 of the conductors 24 a and 24 d. Similarly, the conductors 24 b and 24 e could be formed from one continuous wire and conductors 24 c and 24 f could be formed from one continuous wire. Although the two conductors, such as 24 a and 24 d, are formed from one wire, for simplicity of description, they are still considered as two conductors, such as 24 a and 24 d.

The preceding discussion has centered around a winding 14 having a single slot segment 32 (such as 32 d ₁ of the second conductor 24 d) disposed in the first layer L₁ of the winding and, therefore, a single slot segment 32 (such as 32 a ₂, of the first conductor 24 a) disposed in the second layer L₂. For space concerns, however, it may be desirable to separate the leads 28 of the conductors 24 d,24 e,24 f of the second conductor set 26 b from the leads 28 of the conductors 24 a,24 b,24 c of the first conductor set 26 a. This can be accomplished by disposing the second conductor set 26 b shifted over three additional slots such that the slot segment 32 d ₁ is disposed in slot S_(n-1).

In this case, the second conductor 24 d does not have a single slot segment 32 d ₁ disposed in the first layer L₁, but rather two slot segments 32 disposed in the first layer L₁ adjacent the lead 24 d. The first slot segment 32 d ₁ is disposed in the first layer L₁ of slot S_(n-1) and a second slot segment 32 is disposed in the first layer L₁ of slot S_(n). The other conductors 24 e,24 f of the second conductor set 26 b are disposed in the core slots 16 in a like manner as the conductor 24 d, but for their relative circumferential positions about the stator core 12.

Similarly, the conductor 24 a of the first conductor set 26 a has a slot segment 32 a ₂ disposed in the second layer L₂ of slot S_(n-1) and a slot segment 32 disposed in the second layer L₂ of slot S_(n). The other conductors 24 b,24 c of the first conductor set 26 a are disposed in the core slots 16 in a like manner as the first conductor 24 a, but for their relative circumferential positions about the stator core 12. Similarly, further layers, such as L₃ and L₄, would have two slot segments 32 of each conductor 24 a and 24 d disposed in a certain layer rather than a single slot segment 32 as previously discussed. Furthermore, the leads 28 of the second conductor set 26 b could be further shifted any number of slots 16 resulting in a plurality of slot segments 32 of the second conductor 24 d being disposed in the first layer L₁ and a plurality of slot segments 32 of the first conductor 24 a being disposed in the second layer L₂.

While the above description constitutes the preferred embodiment, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope and fair meaning of the subjoined claims. For example, while the invention is disclosed above in connection with an exemplary stator assembly of bifilar construction, it will be appreciated that the invention contemplates other multi-filar or monofilar configurations. Similarly, while the invention is described above in connection with a “claw pole” type rotor design, the invention contemplates use of the described winding configuration and winding method in conjunction with other types of rotors, such as permanent-magnet non-claw pole, permanent-magnet claw pole, salient field wound and induction type rotors. 

1. A stator assembly for a dynamoelectric machine, comprising: a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core, and a stator winding including a first set of first conductors and a second set of second conductors, wherein each first and second conductor includes a first lead, a plurality of slot segments interconnected with a plurality of end loop segments, the slot segments of the conductors being disposed within the slots of the stator core to define a plurality of concentric winding layers, wherein a first plurality of consecutive slot segments of each first conductor are disposed in a radially-outermost first layer of the stator winding, and at least one first additional slot segment of each first conductor immediately adjacent to the first plurality of consecutive slot segments of each first conductor is disposed in a second, radially-inward winding layer of the stator winding, and wherein at least one first slot segment of each second conductor is disposed in the first layer of the stator winding, and a first plurality of additional, consecutive slot segments of each second conductor is disposed within the second layer of the stator winding.
 2. The stator assembly of claim 1, wherein the first plurality of consecutive slot segments of each first conductor is adjacent to the first lead of the first conductor.
 3. The stator assembly of claim 1, wherein the at least one first slot segment of each second conductor is adjacent to the first lead of the second conductor.
 4. The stator assembly of claim 1, wherein each first conductor further includes a second plurality of consecutive slot segments disposed in a third layer of the stator winding.
 5. The stator assembly of claim 4, wherein the second plurality of consecutive slot segments of each first conductor is adjacent to the at least one first additional slot segment of the first conductor.
 6. The stator assembly of claim 4, wherein each first conductor further includes at least one second additional slot segment disposed in a fourth layer.
 7. The stator assembly of claim 4, wherein at least one second additional slot segment of each second conductor is disposed in the third layer of the stator winding.
 8. The stator assembly of claim 7, wherein the at least one second additional slot segment of each second conductor is adjacent to the first plurality of consecutive slot segments of the second conductor.
 9. The stator assembly of claim 7, wherein a second plurality of consecutive slot segments of each second conductor is disposed in a fourth layer of the stator winding.
 10. The stator assembly of claim 9, wherein the second plurality of consecutive slot segments of each second conductor is immediately adjacent a second lead of the second conductor.
 11. The stator assembly of claim 1, wherein the conductors of each set of conductors are organized into multiple phases defined by a fixed circumferential slot pitch.
 12. The stator assembly of claim 11 wherein the number of the multiple phases equals six.
 13. The stator assembly of claim 1, wherein the first plurality of consecutive slot segments of a particular first conductor are disposed in the slots for the majority of one rotation around the core and the first plurality of the additional, consecutive slot conductors of a particular second conductor are disposed in slots for the majority of one rotation around the core.
 14. The stator assembly of claim 4, wherein at least one of the first conductors of the first set is formed from a continuous conductor and at least one of the second conductors of the second set is formed from a continuous conductor.
 15. A stator assembly for a dynamoelectric machine, comprising: a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core, and a stator winding including a continuous first conductor and a continuous second conductor, wherein the conductors each includes in series a first lead, a plurality of slot segments interconnected by end loop segments, and a second lead, the conductors being disposed within the slots of the stator core to define a plurality of concentric conductor winding layers in which the conductors reside within a given winding layer for nearly one circumferential pass before shifting radially into an adjacent winding layer, wherein a first conductor includes a first plurality of consecutive slot segments disposed in the slots of the stator core for nearly one complete revolution around the stator core within a first winding layer, and a second conductor includes a second plurality of consecutive slot segments disposed in the slots of the stator core for nearly one complete revolution around the stator core within a second winding layer, wherein a first additional slot segment of the second conductor, disposed between the first lead of the second conductor and the first plurality of consecutive slot segments of the second conductor, is disposed in a slot of the stator core within the first winding layer, adjacent to the first plurality of consecutive slot segments of the first conductor, and wherein a first additional slot segment of the first conductor, adjacent to the first plurality of consecutive slot segments of the first conductor, is disposed in a slot of the stator core in the second winding layer, adjacent to the first plurality of consecutive slot segments of the second conductor.
 16. The stator assembly of claim 15, wherein the first additional slot segment of the second conductor is adjacent to the first lead of the second conductor.
 17. The stator assembly of claim 15, wherein the stator winding further includes a third winding layer defined by a second plurality of consecutive slot segments of the first conductor in the slots of the stator core for nearly one complete revolution around the stator core, and a second additional slot segment of the second conductor immediately following the first plurality of consecutive slot segments of the second conductor.
 18. The stator assembly of claim 17, wherein the winding includes a fourth winding layer defined by a second plurality of consecutive slot segments of the second conductor in the slots of the stator core for nearly one complete revolution around the stator core, and a second additional slot segment of the first conductor immediately following the second plurality of consecutive slot segments of the first conductor.
 19. A method of making a stator assembly having a cascaded stator winding about a stator core, the method comprising: inserting a plurality of consecutive slot segments defined on a continuous first conductor and a first one of a plurality of slot segments defined on a continuous second conductor into a series of radial slots in the stator core to define one complete revolution of a radially-outermost first layer of the stator winding, and inserting an additional one of the consecutive slot segments defined on the first conductor and additional slot segments defined on the second conductor into the radial slots to define one complete revolution of a second layer of the stator winding immediately radially-inwardly of the first layer.
 20. The method of claim 19, further including inserting additional slot segments of the first conductor on top of the inserted slot segments of the second conductor.
 21. The method of claim 20, wherein the innermost layer of the stator winding is defined by a second plurality of consecutive slot segments of one of the first and second conductors, and further including completing the innermost layer of the stator winding by inserting a single slot segment of the other of the first and second conductors.
 22. A stator assembly for a dynamoelectric machine comprising: a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core; a stator winding including at least one conductor, wherein each of the at least one conductor includes a plurality of slot segments interconnected by a plurality of end loop segments, the slot segments being disposed within the slots of the stator core to define a plurality of concentric winding layers, and the plurality of end loop segments including a first type of end loop segment interconnecting two slot segments disposed in the same layer and a second type of end loop segment interconnecting one slot segment of one layer with one slot segment of a different layer, wherein fewer than 26% of the plurality of end loop segments are the second type of end loop segments.
 23. The stator assembly of claim 22, wherein fewer than 17% of the plurality of end loop segments are the second type of end loop segments.
 24. The stator assembly of claim 22, wherein at least one of the conductors includes a portion of the conductor which is formed from a continuous wire, the portion includes a group of five consecutive slot segments connected with four end loop segments, wherein two end loop segments of the group are of the first type, and wherein two of the end loop segments of the group are of the second type.
 25. A stator assembly for a dynamoelectric machine comprising: a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core; a stator winding including at least one conductor, wherein each of the at least one conductor includes a plurality of slot segments interconnected by a plurality of end loop segments, the slot segments are disposed within the slots of the stator core to define a plurality of concentric winding layers, and the plurality of end loop segments of the stator include at least one end loop segment having at least two radial adjustments per end loop segment and wherein the number of inward radial adjustments equals the number of outward radial adjustments and at least one end loop segment having one more inward radial adjustment than outward radial adjustments per end loop segment.
 26. The stator assembly of claim 25, further including at least one end loop segment having only one radial adjustment per end loop segment.
 27. The stator assembly of claim 26, further including at least one end loop segment having only two inward radial adjustments and only one outward radial adjustment for each end loop segment.
 28. The stator assembly of claim 25, wherein at least 74% of the plurality of end loop segments being the type of end loop segment having at least two radial adjustments and having and equal number of inward radial adjustments as outward radial adjustments.
 29. The stator assembly of claim 28, wherein at least 83% of the plurality of end loop segments being the type of end loop segment having at least two radial adjustments and having an equal number of inward radial adjustments as outward radial adjustments.
 30. A stator assembly for an automotive alternator comprising: a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core, and a stator winding including a first set of first conductors and a second set of second conductors, wherein each first and second conductor includes in a first lead and a plurality of slot segments interconnected with a plurality of end loop segments, the slot segments of the conductors being disposed within the slots of the stator core to define a plurality of concentric winding layers, wherein a first plurality of consecutive slot segments of each first conductor are disposed in a radially-outermost first layer of the stator winding and at least one additional slot segment of each first conductor immediately adjacent to the first plurality of consecutive slot segments of each first conductor is disposed in a second, radially-inward winding layer of the stator winding, wherein at least one additional slot segment of each second conductor is disposed in the first layer of the stator winding, and a first plurality of additional, consecutive slot segments of each second conductor is disposed within the second layer of the stator winding, and wherein the conductors of each set of conductors are organized into multiple phases defined by a fixed circumferential slot pitch, and the number of the multiple phases equals six.
 31. A stator assembly for an automotive alternator, comprising: a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core; a stator winding including at least one conductor, wherein each of the at least one conductor includes a plurality of slot segments interconnected by a plurality of end loop segments, the slot segments being disposed within the slots of the stator core to define a plurality of concentric winding layers; the plurality of end loop segments of the stator include at least one end loop segment of a first type which connects two slot segments disposed in the same layer and at least one end loop segment of a second type which connects two slot segments disposed in different layers; and wherein the winding includes less than 26% of the end loop segments of the second type.
 32. The stator assembly of claim 31, wherein the winding is arranged as a cascaded winding.
 33. A stator assembly for an automotive alternator comprising: a stator core having a generally cylindrical shape, and a plurality of circumferentially-spaced radial slots defined in a peripheral surface of the stator core; and a stator winding including at least one conductor, wherein each of the at least one conductor includes a plurality of slot segments interconnected by a plurality of end loop segments, the slot segments being disposed within the slots of the stator core to define a plurality of concentric winding layers, wherein at least 74% of the plurality of end loop segments being an end loop segment of a first type which has at least two radial adjustments with the number of inward radial adjustments being equal to the number of outward radial adjustments; and wherein the plurality of end loop segments include at least one end loop segment having one more inward radial adjustment than outward radial adjustments per end loop segment, at least one end loop segment having only one radial adjustment per end loop segment, and at least one end loop segment having only two inward radial adjustments and only one outward radial adjustment for each end loop segment. 